Rack-aisle freezing system for palletized product

ABSTRACT

An installation and method for freezing and cold storage of palletized product. A chiller is provided in the interior of a cold storage warehouse space that maintains the temperature of ambient air within the space below freezing. A plurality of racking structures each define an air flow chamber having air intake openings on opposite sides thereof and an air outlet to enable freezing air to be drawn into the chamber through the intake openings and exhausting into the warehouse space. Pallets on pallet guides are pressed against the intake openings such that freezing air is drawn through the palletized product to thereby quickly freeze the product. The pallet structure and air flow chambers are arranged in spaced-apart rows to enable a forklift to pass down the aisles so as to place and remove the palletized product.

This application claims the benefit under Title 35, U.S.C. §119(e) ofU.S. Provisional Patent Application Ser. No. 61/241,065, titledRACK-ISLE FREEZING SYSTEM FOR PALLETIZED PRODUCT, filed on Sep. 10,2009, the disclosure of which is expressly incorporated by referenceherein.

The present disclosure relates to a warehouse or structure that massfreezes and stores bulk foods and other products.

FIG. 1 is a perspective view of a warehouse incorporating a freezingsystem in accordance with the present disclosure;

FIG. 2 is a diagrammatic top view of a freezer warehouse incorporatingthe system of the present disclosure;

FIG. 3 is a perspective view of the interior of the freezer warehouse;

FIG. 4 is a perspective end view showing a racking arrangement;

FIG. 5 is a perspective view of two rows of racking;

FIG. 6 is a diagrammatic perspective view showing the flow of chillingair through the palletized product;

FIGS. 7 and 8 show loading of the palletized product into the racks;

FIG. 9 is a perspective view of the racking structure as seen from theinterior air chamber; and

FIG. 10 is a diagrammatic view showing the flow of air through thepalletized product into the interior air chamber.

According to the present disclosure, a large warehouse, building, orstructure, such as warehouse 2 shown in FIG. 1, is used as a giantfreezer that both freezes and maintains perishable foods or likeproducts. Large pallets of items such as meats, fruits, vegetables, andprepared foods can be taken to this warehouse and promptly frozen inblast rooms. The product is then moved to the storage part of thewarehouse where it is maintained at a frozen temperature until removed.

Unlike two-stage freezer warehouses, this disclosure describes aspecially configured rack system that assists freezing the productdirectly in the open warehouse space. In essence, the system describedherein is a one-stage freezing storage system, rather than a multi-stagefreezing storage system. It is appreciated that fresh-packed fruits,vegetables, and other products can be chilled to a desired temperature.

A top view of the inside of warehouse 2 shown in FIG. 2 depictingseveral rows of palleted product. Each pallet 4 abuts a chamber 6. Inthis illustrative embodiment, pallets 4 are positioned several high onopposing sides and along chamber 6. Cold air produced in warehouse 2 isdrawn through spacers 20 (see FIG. 6) separating rows of cases ofproduct on the pallet. This air cools the product down while being drawninto chamber 6 indicated by directional arrow 16. In an illustrativeembodiment, and as further discussed herein, openings 30 along theperiphery of chamber 6 mate with cases 22 on the pallets 4 (see FIG. 9).The only significant way to move the cold air inside warehouse 2 is bygoing through and/or around the product on pallet 4. The air 16 drawninto chamber 6 can then be recooled and recirculated, or exhausted.Because the cold air moves around product prior to entering chamber 6,it provides an efficient means for freezing.

Chillers 8 inside warehouse 2 produce the cold air that flows throughaisles 10 and into chambers 6. It is appreciated that chillers 8 can bepositioned in different locations as needed inside warehouse 2. As shownin FIG. 2, chillers 8 are positioned remotely from chambers 6. Thechilled air passes through open spaces near or through cases of productin order to enter chamber 6. Air handlers, such as fans 12 inside or inair flow communication with chamber 6 assist in drawing the air withinwarehouse 2 through the palletized and/or through the product cases andinto the channel. Continuing this process freezes the product as well asmaintains its frozen condition. Without blast freezers that initiallyfreeze product only to then move it to warehouse aisles, more space canbe dedicated to either more rows of chambers 6 or more aisle space 10.Increasing capacity or maneuvering room in a warehouse is beneficial.

A top perspective view of the inside of warehouse 2 is shown in FIG. 3,This view shows rows of racking 14 between aisles 10 and chamber 6. Inthis view the actual chambers 6 are obscured because end caps 15 arecovering their ends. A plurality of fans 12 are shown at the top withtop panel 17 covering chamber 6. This view demonstrates how aisles 10can be widened to accommodate more forklifts 18. This view also showshow many cases of product on pallets 4 can be stacked in these rows. Inthis illustrative embodiment, the pallets are stacked five high. Thisnumber can vary, however, depending on the needs of the warehouse andthe size, configuration, and weight of the cases on the pallets. Thespace savings can also be appreciated from this view. The entirewarehouse uses the same rows to both cool and store palleted product.This is more efficient than a conventional warehouse having separateblast freezing rooms. This new configuration not only requires lessspace, but it also no longer requires transporting the pallet from theblast room to a separate storage location in the warehouse.

An end view of chamber 6 with racking 14 on each side holding pallets 4is shown in FIG. 4. As further illustrated, fan 12 draws air in asindicated by directional arrow 16 through and around cases of product 22on pallets 4 before entering chamber 6. End cap 15 has been removed fromthis view, but otherwise prevents air from entering chamber 6 at the endof the row. It is appreciated that in this illustrative embodiment,storage management in warehouse 2 can also be improved by using a singlepallet deep configuration. There is now more room for forklift 18 tomaneuver, as well as pick and stack product.

Another perspective view of chamber 6 located between rows of racking 14is shown in FIG. 5. This view further demonstrates the ease within whichpallets 4 of product can be accessed by forklift 18 during freezing orwhile maintaining their frozen condition. Conventional cooled warehousesstore their pallets of product two or more pallets deep. This creates aless efficient stocking and retrieval system.

An illustrative pallet 4 of cases 22 of product is shown in FIG. 6. Inthis illustrative embodiment, a freezer spacer 20 is placed between rowsof individual cases 22 of product in order to provide air pathways 24.In addition, pathways 24 provide more passages through which air flowcan enter chamber 6. Illustratively, spacers 20 can be made from aplastic mesh. Alternatively, they may be strips of solid material, suchas wood or metal. It is contemplated that other like materials andstructures can work to create air pathways by separating one row ofcases 22 from another. It is further appreciated that some containers,such as turkey and ham boxes, for example, are fabricated with holes inthe sides intended to allow air-flow for quicker freezing. Stacks ofthese cases may not require the spacers in order to freeze properlyusing the system disclosed herein.

A perspective view of a pallet 4 supporting a plurality of cases 22 andmoving in direction 28 toward chamber 6 is shown in FIG. 7. To assistfacilitating moving the chilled air from warehouse 2 into chamber 6, aplurality of openings 30 are positioned in wall 32 of racking 14. Wall32 along with covers 17 and end cap 15 form chamber 6 (see, also, FIG.3). In this embodiment, pallet 4 is positioned against periphery 34, 40,and 42 of air intake opening 30 preventing air from entering chamber 6except through and around cases 20. To assist in this endeavor, spacedapart pallet support guides 36 are positioned at the illustrativelylower end periphery 34. The space 38 between pallet guides 36 receivespallet 4 ensuring stacked cases 22 will be properly positioned in frontof opening 30. It is appreciated that, as seen in FIGS. 4 and 5, forexample, pallets can be stacked vertically. It is further appreciatedthat for each pallet 4 there is a pair of pallet guides 36 or likestructures to help guide it to the opening. It is also appreciated thatthere can be multiple openings 30 both vertically and laterally alongboth sides of chamber 6 that employ multiple pairs of channel guides 36.

Another perspective view of pallet 4 moving in direction 28 towardsopening 30 is shown in FIG. 8. This view shows seals 40 and 42positioned about the periphery 34, 40, and 42 of opening 30. It isappreciated that cases 22 will abut against seals 34, 40, and 42 tomitigate the potential for air to enter chamber 6 adjacent wall 32,without first going over and around cases 22. It is further appreciatedthat there can be upper and lower horizontal seals 42 and 34,respectively, that abut the top and bottom rows of cases 22 on pallet 4.

It is further appreciated that seal 42 can be selectively verticallyadjustable in directions 44 and 46 via adjustable bracket 48 to abut thetop row of cases 22 on pallet 4. In the illustrative embodiment, bracket42 may include detents, pins, or other structures that selectivelyengage corresponding recesses, holes, etc., to secure bracket 48 to adesired height. This flexibility is useful because depending on theproduct being frozen, the pallet height may vary. Directing airflowthrough and around cases 22 on pallet 4 means it is preferable not tohave an opening either above or below the product which would create anon-desirable path of least resistance for the air to flow to enterchamber 6. It is contemplated that for each stack of pallets, adjustablepanel 48 can be moved to the desired position depending on the height ofcases 22. This view also shows a second upper row storage system forpallets 4 that includes additional pallet guides 36 to assistmaintaining proper positioning of pallets 4 along a column. It isfurther contemplated that additional adjustment brackets can be moved tothe appropriate location that directs air through pallets 4, rather thanjust around them. It is still further appreciated that the configurationof racking 14 with openings 30 and guides 36 can all be configured toaccommodate conventional palleting and pallet stacking systems used in avariety of warehouse environments.

A perspective view inside chamber 6 looking toward opening 30 withpallet 4 and cases 22 pushed up against seals 34, 40 and 42 is shown inFIG. 9. From this perspective, it is appreciated that the combination ofcases 22, spacers 20, and seals 34, 40 and 42 generally prevent airflowfrom entering chamber 6 except through space 24 created by spacers 20.This embodiment also shows a panel 48 placed above pallet 4 preventingair from simply entering chamber 6 above cases 22. It is appreciatedthat panel 48 is not only adjustable, but can also be either separate orattached to seal 42 as needed to provide the flexibility allowingstacked pallets 4 of a variety of heights to limit airflow into chamber6. This view also shows illustrative panel 48 and pins 52 thatillustratively engage the periphery 30 of periphery 34 to selectivelyhold panel 48 in place. It is appreciated that a variety of latches,clasps, etc., can be used to hold structures that prevent air fromflowing into chamber 6 from undesired regions. This view showsadditional panels 50 along the row of racking 14 that are configured toreceive additional pallets that are subject to the same restriction ofairflow flowing through the cases 22.

Another perspective view from inside chamber 6 is shown in FIG. 10. Thisview demonstrates the airflow 16 that occurs when pallet 4 and cases 22are pressed against the periphery 34, 40, and 42 of opening 30, as shownfrom the inside of warehouse 2. The predominate pathways are thespacings 24 created by spacers 20 between cases 22. This chilled airpasses over and under each case 22 reducing their temperature until itreaches freezing. Once frozen, cold air can be used to maintain thefrozen state of the product inside cases 22 until they are ready to beremoved from warehouse 2.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplification set out hereinillustrates an embodiment of the invention, in one form, and suchexemplification is not to be construed as limiting the scope of theinvention in any manner. Although the present disclosure has beendescribed with reference to particular means, materials and embodiments,from the foregoing description, one skilled in the art can easilyascertain the essential characteristics of the invention and variouschanges and modifications may be made to adapt the various uses andcharacteristics without departing from the spirit and scope of theinvention.

What is claimed is:
 1. An installation for freezing and cold storage ofpalletized product, comprising: a cold storage warehouse space; at leastone chiller in said warehouse space that produces freezing air andmaintains the temperature of ambient air in the warehouse space belowfreezing; at least one air flow chamber including a plurality of airintake openings on opposite sides thereof, at least one air handler andan air outlet opening to enable freezing air to be drawn into thechamber through the intake openings and exhausted into the warehousespace through the air outlet; and a plurality of pallet guides forsupporting pallets of product to be frozen in sealing engagement withthe air intake openings, whereby freezing air is drawn through thepalletized product to thereby quickly freeze the product; wherein the atleast one chiller is mounted in the warehouse space remotely from thechamber.
 2. The installation of claim 1, wherein the chamber has aplurality of vertically spaced horizontal rows of said air intakeopenings.
 3. The installation of claim 2, including seals on theperiphery of said air inlet openings adapted to engage the palletizedproduct to facilitate drawing the freezing air through the palletizedproduct.
 4. The installation of claim 1, including seals on theperiphery of said air inlet openings adapted to engage the palletizedproduct to facilitate drawing the freezing air through the palletizedproduct.
 5. An installation for freezing and cold storage of palletizedproduct, comprising: a cold storage warehouse space; at least onechiller in said warehouse space that produces freezing air and maintainsthe temperature of ambient air in the warehouse space below freezing; aplurality of air flow chambers arranged in spaced-apart rows, each saidchamber having at least one air intake opening, at least one air handlerand an air outlet opening to enable freezing air to be drawn into thechambers through the air inlets and exhausted into the warehouse spacethrough the air outlets; and a plurality of pallet guides arranged atthe chamber openings for supporting pallets of product to be frozen insealing engagement with the air intake openings, whereby freezing air isdrawn through the palletized product to thereby quickly freeze theproduct; said rows of chambers and their respective pallet guides beingspaced apart from adjacent rows of chambers and pallet guides to form atleast one aisle sufficiently wide to accommodate a forklift to passtherebetween; wherein the at least one chiller is mounted in thewarehouse space remotely from the chambers.
 6. The installation of claim5, wherein the rows of chambers are substantially parallel to eachother.
 7. The installation of claim 6, wherein the chambers each have aplurality of said air intake openings and respective pallet guides onopposite sides of the chambers.
 8. The installation of claim 7,including seals on the periphery of said air inlet openings adapted toengage the palletized product to facilitate drawing the freezing airthrough the palletized product.
 9. The installation of claim 6,including seals on the periphery of said air inlet openings adapted toengage the palletized product to facilitate drawing the freezing airthrough the palletized product.
 10. The installation of claim 5,including seals on the periphery of said air inlet openings adapted toengage the palletized product to facilitate drawing the freezing airthrough the palletized product.
 11. A method for quickly freezingpalletized product in a cold storage warehouse space, comprising:producing flowing freezing air by means of at least one chiller tothereby cool ambient air within the warehouse space to a sub-freezingtemperature; providing an airflow chamber that is substantially sealedand has a plurality of air intake openings on opposite sides thereof;positioning a plurality of palletized product stacks against the airintake openings; and creating a negative air pressure within the airchamber to thereby draw freezing ambient air from the warehouse spacethrough the palletized product and through the air intake in openings tothereby freeze the product.
 12. The method of claim 11, wherein thechiller is located remotely from the chamber.
 13. The method of claim12, including pressing the palletized product stacks against sealslocated on the periphery of the air intake openings.
 14. The method ofclaim 11, including pressing the palletized product stacks against sealslocated on the periphery of the air intake openings.
 15. The method ofclaim 11, including: providing a plurality of the air flow chambers,which chambers are arranged in spaced-apart rows forming aislestherebetween; and positioning the palletized product against the airintake openings by means of a forklift that moves down the aisles. 16.The method of claim 15, wherein the chambers have vertically spacedhorizontal rows of the air intake openings.
 17. The method of claim 11,wherein the chambers have vertically spaced horizontal rows of the airintake openings.
 18. An installation for chilling and cold storage ofpalletized product, comprising: a cold storage warehouse space; at leastone chiller in said warehouse space that produces cold air and maintainsthe temperature of ambient air in the warehouse space at a temperaturesufficient to chill the product; at least one air flow chamber includinga plurality of air intake openings, at least one air handler and an airoutlet opening to enable the ambient air to be drawn into the chamberthrough the intake openings and exhausted into the warehouse spacethrough the air outlet; a plurality of pallet guides for supportingpallets of product to be chilled in sealing engagement with the airintake openings, whereby chilling air is drawn through the palletizedproduct to thereby quickly chill the product; wherein the at least onechiller is mounted in the warehouse space remotely from the chamber; andwherein the chamber has a plurality of said air intake openings onopposite sides thereof.
 19. An installation for chilling and coldstorage of palletized product, comprising: a cold storage warehousespace; at least one chiller in said warehouse space that produces coldair and maintains the temperature of ambient air in the warehouse spaceat a temperature sufficient to chill the product; a plurality of airflow chambers arranged in spaced-apart rows, each said chamber having atleast one air intake opening, at least one air handler and an air outletopening to enable the ambient chilling air to be drawn into the chambersthrough the air inlets and exhausted into the warehouse space throughthe air outlets; and a plurality of pallet guides arranged at thechamber openings for supporting pallets of product to be chilled insealing engagement with the air intake openings, whereby ambientchilling air is drawn through the palletized product to thereby quicklychill the product; said rows of chambers and their respective palletguides being spaced apart from adjacent rows of chambers and palletguides to form at least one aisle sufficiently wide to accommodate aforklift to pass therebetween; wherein the at least one chiller ismounted in the warehouse space remotely from the chambers.
 20. Theinstallation of claim 19, wherein the chambers each have a plurality ofsaid air intake openings and respective pallet guides on opposite sidesof the chambers.